Method of making paper boxes



March 24, 1931. H. CARLE METHOD OF MAKING PAPER BOXES Original Filed April 27, 192

INVENTOR ATTORNEYS Patented Mar. 24, 1931 stares HARoLn oARLnor B FFALO, NEW YORK, ASSIGNQRTO F. i. BURT COMPANY, LIMITED,

or ronorrro, CANADA, a coaroiaarron oreenana METHOD OF MAKING BAPER'BOXES Original application gfiled A rii 27, was, Serial No. 635,078. Patent No. 1,693,136. -Divided.-and this application filed July 19, 1928, Serial NOLESSEDQ. Etenewedflanuary 15, 133.1.

This invention relates to methods of manufacturing boxes,and with respect to its more specific features to the methodsof manufacture of a box base composed of paper and similar fragile material which, while adapted in its rough or partly finished condition to serve as a tray or. container, is more especially designed to be further operated onand especially to be coveredwith ornamental material so as to produce a finished and durable paper box,.by a few simple operations and with economic use of paper.

One of the-objects of the invention is the provision of a method of making a simple rec tangular box base of the character referred to. r

Another object of the invention is the provision of a practical. and economic method of manufacturing a small relatively stiff, rectangular, paper box composed of relatively stiff body material covered with material of a finishing orornamental character and one in which the faces of the finished box, es-

pecially the exterior faces, are smooth and even throughout, free fromblisters, puckers, ridges and the like and in general free from blemish.

Other objects of the invention will in part be obvious and will in part appear hereinafter.

The invention accordingly comprises the several steps and the relation and order of one or more of such steps with respect to each of the others which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.

For a fuller understanding of the nature and objects of the invention reference should be had to the following detailed description taken in connection with the accompanying drawing, in which: 1

Figure 1 is a perspective view of the bodyblank held on a mandrel or former,

Fig. 2 is a view similar to Fig. 1, after adhesive has been applied to the body-blank,

Fig- 3 is-an edge view diagrammatically'il l-ustrating a bulged cover-blankin proximity to the body-blank, in .th e. operation of apply ing'the cover-blank,

' Fig. 4c folded so that the flaps lieagainst the sides of the mandrel, portions of the folders being shown; also the-stay strip is shown pan tially applied,

, 5 152,. 6 is a view of the folded elements of Fig-.5, with a finishing strip on the stay strip, p i

Fig. 7 is a perspective view of the box base, covered with finishing strip and ust afterbeing withdrawn from the mandrel or former,

Fig. 8 is a transverse sectionof boxafter finishing strip has been turned over the edges Fig. 9 is a perspective viewzo't the finished box, partly broken away to show interior construction, and

b Figs. 1 0 and 11 are enlarged details of the It will facilitatethe disclosure to first describe the box base, which may be made by the method herein described, and which is designed to be utilized as a foundation to be finished or ornamented as may be desired. The head of the box base includes the head 1 of a corner-cut rectangularbody-blank, and theflange of the box-base includes the flaps 2, 3, 4 and 5 of the same blank, the flaps being integral with the head of the blank, and being folded'on scored lines into position at right angles to the head 1, and so that adjacent flaps closely adjoineach other at the corners .of the rectangular element thus produced.

Facing the outside of the head 1 is a soft, pliable corner-cut cover-blank having a central or head portion 6 which registers with. the head 1 of the body-blank, certain integral portions,or flaps, of the cover-blank extending to provide marginal portions 7 of the cover-blank which marginal portions are adhesively secured to the flaps 2, 3, 4 and 5 as indicated in Fig. 4.. A stay strip 8 is adhesively secured directly to the exterior faces of the flaps of the body blank so as to secure each oth r peripherally of the flange.

side the edges of the cover-blank where the latter lies on the flaps. The stay strip and the cover-blank are of the same thickness so that the exterior surface of the flange of the box base is smooth and even except for the joint between the stay strip and the proximate outer edges of the cover-blank. The stay strip preferabl closely abuts the outer edges of the cover-blank so that the ,ioint therebetween is not marked. In this wise the finishing strip 9. which surrounds the flange exteriorlv and i s adhesively attached both to the stay strip and to the cover blank and overlies the joint between these last two elements, will lie smoothly and evenly and present an exterior surface substantially free from pronounced ridges which otherwise might be caused bv pressing: the soft finishing paper at the ioint between the stay stri an d the outer edges of the cover-blank on the flange.

To obviate the chance of spacing the stay strin and the edges of the cover-blank at such distances from each other as Wonld result in an irregular joint therebetween peripherally of the flange. the outer edges 40 of the cover-blank. where it lies on the flaps, are straight. these edsres be ng in a ...nment with The proximateedge 41 of the stay strip is also straight. Not only is the joint referred to made more uniform by utilizing straight edges of the. covering material. but the automatic application of the stay strip and cover-blank in effective positions is much facilitated as will appear further on. As illustrated in Figs. 6. 9, 10 and 11. the width of the finishing strip 9 is such that it extends from the bottom of the flange to and beyond the open end of the box base. so that its outer, extended portion 4-2 may be folded across the open edge of the flange and down into the box base where it may be Dressed against the inner walls of the box base to form a completed box.

It will be observed that in the formation of the box base only two pieces of paper are required in addition to the body-blank. and it will be further observed that the entire exterior surface of the head and flaps of the body-blank is covered by the cover-blank togather with the stay strip, the latter covering' all the exterior surface of the flaps not covered by the cover-blank. Consequently the structure provides for the most economic use of the paper material.

Coming, now to the method of making the box base a flat. corner-cut, rectangular, bedyblank having the head 1 and the flaps 2. 3, 4t and 5, is illustrated in 1. To facilitate folding of the flaps relative to the rectangiu lar head 1 on predetermined right lines, the blank is scored or slit so as to weaken the same along such lines. 10. on one face of the corner-cut blank. The corner-cut bodyblank is of relatively stifi, bendable paper,

'lustrated the coverblank as for instance, cardboard, straw board, pasteboard, or the like. In Fig. a the cover sheet, or cover-blank is illustrated. The cover-blank may be thinner than the bodyblank and is of relatively soft, pliant paper and pref rably hasan ext glazed or other ornamental surface. In form ilformed from a r ctanguiar piece of paper having the corner cut away as indicated at 11, for a purpose hereinafter described.

For convenience in performing the pressing and felt-1111p; operations and applying the'stay strip and he finishing'strip, a rectai'igular mandrel 12 may be employed, and th head 1 of the body-blank may be held on the outer end of the 7 auction, so that there are no mechanical parts to interfere with the proper folding and positioning of the materials. F or gumming the cover-blank to the body-blank any suitable adhesive may be employed and is applied to the flaps of he body-blank and preferably also over the. head 1 on that face of the body-blank having the scores 10, as illustrated by the brokenlines in Fig. 2.

In applying the cover-blank, or cover sheet. to the body-blank, the cover sheet is first bulged, or curved, as indicated in Fig. 3, so that the convexity of the curve faces the flat body-blank, and thereafter the center of the bulged portion is first applied to the central summed portion of the body blank, the cover-blank thereafter being progressively pressed into contact with the bodyuntil the cover blank lies evenly and smooth ly across the head 1 and on the flaps 2, 3, 4 and 5 of the flat, unfolded body-blank, and adheres to the flaps, as illustrated in F ig. 4. Thereafter, while the adhesive is moist, the flaps 2, 3, 4 and 5, with the adhering coverblank portions, are folded on lines coincident with the edges of the head 1 in directions tending to tauten the cover sheet over the head 1 between. opposite flaps, the flaps of the body-blank being thus caused to assume the position they would occupy in the flange of the box base to be formed. In the present embodiment the folding takes place on the weakened lines 10 WlliCliilQfiDltGlf] mark out the edges of the head of the box base. By first adhesively attaching the cover-blank as hereinbefore described, the folding movement, away from the covered face of the head 1, tends to tauten, or stretch, the cover sheet, and all danger of fracturin the cover sheet isavoided by reason of the ability of the cover sheet to slip on the moist adhesive surface of the bouyblank without detracting from eflicient tautening and stretching of said sheet. As the opposite flaps fold in opposite directions the cover sheet is tautened in each of opposite directions at right angles mandrel 12. as by bank from the central portion outwardly opened, as the folding of the flaps takes place,

the corners of the bottom of the box are surely andcleanly defined, the outer face of the bod ,-blan having already been broken by the scoring. b.

it 1S very des1rable that the bottom of the box base shall beof predetermined shape;

in the present instance that it shall befiat I overall. To assist in maintaining the fiat condition of the bottom, the head 1 is pressed, espec ally arhacent its margin, so as to prevent outward, bulging distortion thereofluring the folding of the flaps. To effect this presslng a presser plate 13 may be employed. This plate may be of substantially the same dimensions as the head of the body- 7 blank and may be -yieldingly pressed against the full area of the rectly opposite said head. By making the pressing face of this plate 13 flat and smooth,

' its pressurcon the cover-blank assists in giving a smooth and even surface to the coverblank opposite the head 1 and causes the cover-blank to adhere to the head 1 of the body-blank. F or folding the flaps the folding plates 14 may-be employed. These plates substantially the same in Width as the flaps of the body-blank.v By moving them toward the mandrel they initiate the folding of the flaps, and also cooperate with the mandrel subsequently to squeeze the cover sheet material on the flaps so as to effect firm adherence'between the cover material and the flaps after the folding of the flaps and the stretching, or tautening, of the cover sheet have been effected.

While the flaps and the cover material thereon are held folded, and preferably also while the head is pressed by the plate 13, the stay strip material 8 is applied exteriorly across the joints 15, between the adjacent folded flaps, and adhesively directly secured on the exterior faces of-the flaps 2,3, l and 5 in order to join adjacent flaps to each other and permanently Y maintain the flaps in folded relation to form the flange. The stay strip is narrower than the upstanding length of the flange and has a straight edge l1 which may lie close to and, in abutting relation to the outer straight edges 40 of the flaps of the cover-blanlrwhich are adhesively secured to the flaps of the bodyblanlr. In this wise the stay strip 8 may be applied at a point on the folded flaps of the body-blank, and the mandrel with the flaps held thereon, rotated on an axis passing through the center of the head 1, with the result that the stay strip will be Wound upon the exterior of the flaps and its edge 41 will be symmetrical with'and lie close to the straight outer edges of the cover-blank. While some little spacing .is

cover blan'k dipermissible between the inner edge .of-thestay strip andthe outer edges ,of the cover-blank, it is preferred that the stay strip should closely :abut the edges of the cover-blank and provide afiller' which, as it were, raises the surface of the body flaps to one flush with the of the of'the cover sheet, the stay strip covering substantially all of the ex.- teriorsurface of the flaps of the body-blank except that covered by the cover sheet.

In many. cases millions of boxes of the aracter herein referred to are "required to be exactly the same in dimension and appear ance.

By assemblingthe cover-blank and bodyblank and folding'and-staying the same as hereinbeforedescribed, it is practically assured that the resultant box bases formed from simil-ar sized blanks, respectively, will themselves be of exactly the same dimension and i appearance The stay strip 8 is. applied while the cover-blank and the body-blank are held adhesively assembled .in folded relation, so that there is practically no chance for the folded parts to move fromestablished rela tion. I I Y It will beobserved that the cover-blank is applied to the head of the body-blank in such position tl1at,at the corners of said-head, the edges ofthe cover-blank substantially register withsaidcorners at the intersection of the side edges of the cutouts 16 of the bodyblank, and do not extend into thecutouts. In

this wise the exterior ofthe-head of the bodyblank may be substantially completely covered, by, the cover-blank and the folding of the body-blank flaps accomplished so as to fold the cover materialw-ithout gathering'of the coverimaterial at the corners. It is'tozbe understood that theterm box'base herein .em-* ployed is intended to include box covers as Well,t=he invention bein equally adapted -for either. Reference-is made to applicahts Patent No. 1,693,136, ofwhich this applicationis a division.

Thus by the above described construction and operations are accomplished, among others, the objectshereinbefore referred to.

Having described my invention, What I claim aslnewand desire to secure :by Letters Patent, is v 1. The method-of making a box which ineludes gumming a pliant cover sheet to the flaps of aflat rectangular corner-cut bodyblanlrof relatively stiff bendable material so that saidsheet lies within the margin of andon the head of the body-blank and laps onto the flaps thereof, thereafter, while the adhesive is moist, folding the flaps with their attached sheet portions, on lines coincident with lUl) the edges of said head to tauten said sheet over said head between opposite flaps and to dispose said flaps to form the flange of the box.

'2. The method of making a box'which includes guniming a pliant cover sheet to the flaps of a flat rectangular corner-cut bodyblank of relatively stiff bendable material so that said sheetlies within the margin of and on the head of the body-blank and laps onto the flaps thereof, thereafter, while the adhesive is moist, folding the flaps with their atto the flaps, while holding the flaps in folded relation by a squeezing pressure applied directly to the cover sheet'material on the flaps, so as to join adjacent flaps to each other and permanently maintain the flaps in folded relation to form the box flange.

3. The method of making a box which includes gumming a pliant cover sheet to the flaps of a flat rectangular corner-cut bodyblank of relatively stiff bendable material so I a that said sheet lies within the margin of and on the head of the body-blank and laps onto the flaps thereof,thereafter, while the adhesiveis moist, folding the flaps with their attached sheet portions, on lines coincident with the edges of said head to tauten said sheet over said head between opposite flaps and to dispose said flaps to form the flange of the box, pressing said head so as to prevent outward bulging distortion thereof during said flap folding operations and applying strip material exteriorly across the joints between adjacent folded flaps and gumming the strip material to the flaps to permanently maintain the flaps in folded relation while holding the flaps folded and while pressing said head.

4. The method of making'a box which includes gumming a pliant cover sheet to the flaps and head of a flat rectangular corner-cut body-blank of relatively stiff bendable material so that said sheet lies within the margin of and on the head of the body-blank and laps onto the flaps thereof, thereafter, while the adhesive is moist, folding the flaps with their attached sheet portions, on lines coincident with the edges of said head to tauten said sheet over said head between opposite flaps and to dispose said flaps to form the flange of the box, pressing said sheet against the head of said body-blank and preventing outward bulging distortion of the sheet covered head during said flap folding operations and applying strip material exteriorly across the joints between adjacent folded flaps and gumming the strip material to the flaps to permanently maintain the flaps in folded relation while holding the flaps folded and while pressing said head. V

5. The method of making a box which in cludes, providing a flat rectangular cornercut body-blank oflrelatively stiff bendable material and a pliant cover sheet of a size adapted to lie on the head and lap onto the flaps of the body blank,'thereafter bulging said sheet, thereafter gumming the sheet to the head and flaps of the body-blank from the center of the head outwardly, first pressing the center of the bulged portion to the central portion of said head and thereafter progressively pressing the other portions into contact, thereafter folding the flaps with their attached sheet portionsvso that said sheet will be disposed across the convexity of the lines of fold, and thereafter staying the laps in their folded relation.

6. The method of making a box which includes, providing a flat rectangular corner cut body blank of relatively stiff bendable material and a pliant cover sheet of a size adapted to lie on the head and lap onto the flaps of the body-blank without intersecting the corner-cuts of the latter, thereafter bulging said sheet, thereafter gumming the sheet to the head and flaps of the body-blank from the center of the head outwardly, first pressing the central portion of said head and thereafter progressively pressing the other portions into Contact, thereafter folding the flaps with their attached sheet portions so that said sheet will be disposed across the convexity of the lines of fold, and thereafter staying the flaps in their folded relation.

7. The method of making a box which includes, providing a fiat rectangular cornercut body-blank of relatively stiif bendable material having weakening scores outlining the edge of the head thereof, and a pliant cover sheet of a size adapted to cover said head and lap onto the flaps of said body-blank without intersecting the corner-cuts of the latter, gumming the head and flaps of said body-blank on the scored face thereof, bul ing said cover sheet and thereafter applying the same to the gummed head and flaps of the body-blank, first pressing the center of the bulged portion to the central gummed portion of said head and thereafter, progressively pressing the other portions into contact from the central portions outwardly, thereafter folding the flaps on said scores, with their attached sheet portions,'so that said sheet will be disposed across the convexity of the lines of fold exteriorl pressing the covered head, so as to prevent outward bulging distortion thereof, during said flap folding operations and staying said flaps in their folded relation while pressing said head.

8. The method of making a box which includes superposing a cornercut cover sheet on a corner-cut body-blank of relatively stiff material having weakening scores outlining the head thereof, and adhesively joining the superposed flaps of the blank and sheet, the ends of the flaps of said sheet being inside the the center of the bulged portion to ends of the flaps of said blank, thereafter while the adhesive is moist, folding the adhesively attached flaps in directions to tauten said sheet over the head of said body-blank, and thereafter winding a filling strip exte riorly on the folded body-blank flaps outside the ends of said cover sheet flaps and across the joints between said flaps and adhesively securing said fillingstrip in place.

9. The method of making a box which in cludes providing a corner-cut body-blank of relatively stifi' material having weakening scores outlining the edge of the head thereof, and a pliant corner-cut cover sheet, bulging said cover sheet, and thereafter adhesively applying the cover sheet to the head of said body-blank by pressure progressing outward- 1y from the center of said head.

10. The method ofmaking a box which includes providing a corner-cut body-blank of relatively stifi' material having weakening scores outlining the edge of the head thereof,

and a pliant corner-cut cover sheet, bulging said cover sheet, and thereafter adhesively applying the cover-sheet to the head and flaps of said body-blank by pressure progressing outwardly'from the center of said head. a 11. The method of making a box which includes providing a corner-cut body-blank of relatively stiff material having weakening scores outlining the edge of the head thereof, and a pliant corner-cut cover sheet, bulging said cover sheet, and thereafter adhesively applying the cover sheet to the head and flaps of said body-blank by pressure progressing thereafter progressively pressing the other 4 portions of said blank and cover sheet into contact with eachother, and thereafter folding'the flaps, with their attached cover sheet portlons, on said scores in directions tending to open said scores and tauten said sheet over said headbetween opposite flaps and to dispose said flapsto form the flange of a box. In testimony whereof, I afiix my signature.

[ A OLD CABLE.

outwardly from the center of said head,

thereafter while the adhesivev is moist, folding the adhesively attached flaps in directions to tauten said sheet over the head of said body-blank, and thereafter winding a filling strip exteriorly on the folded body-blank flaps outside the ends of said cover sheet flaps and across the oints between said flaps and adhesively securing said filling strip in place.

12. The method of making a box which includes providing a 'corner-cutbody-blank of relatively stiff material having weakening scores outlining the edge of the head thereof, and a pliant corner-cut cover sheet, bulging said cover sheet, and thereafter adhesively' applying the cover sheet to the head and flaps of said body-blank by pressure progressing outwardly from the center of said head, thereafter While the adhesive is moist, folding the adhesively attached flaps in directions to tauten saidsheet over the head of said body-blank, andithereafter winding a filling strip exteriorly on the folded bodyblank flaps outside therends of said cover sheet flaps and across the joints between said flaps and adhesively securing said filing strip in place, and during said folding pressing the head of said attached body-blank and cover sheet to prevent their outward bulging.

13. The method of making a box which in- 

